C2 2005
C2 2005
C2 2005
1i
Engine types
DV 4 TED4 1.4 16V HDi 8HY 6 ATED4 1.6 16V HDi 9HX
HFX X X
8HZ X X X
C2 C3 C3 PLURIEL
VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year. It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.
PRIVATE CARS
PRIVATE CARS
C2-C3-C3 PLURIEL
The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer. The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically for further information and to obtain any possible updates.
2005
The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden.
2005
PRESENTATION
THIS HANDBOOK summarises the specifications, adjustments, checks and special features concerning CITRON private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C2-C3-C3 PLURIEL and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.
IMPORTANT
If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example: - INSUFFICIENT INFORMATION - SUPERFLUOUS INFORMATION - NEED FOR MORE DETAILS Please send your comments and suggestions to: CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
CONTENTS
GENERAL C2 Vehicle identification C3 C3 Pluriel Operations following a repair C2 Capacities C3 C3 Pluriel TOTAL recommended lubricants ENGINE Specifications Tightening torques: engines all types Cylinder head tightening: all types Auxiliary drive belt Checking and setting the valve timing Checking the oil pressure Valve clearances 37 - 38 39 - 72 73 - 74 76 90 133 134 1-2 3-5 6-7 8-9 11 12 13 14 - 36 INJECTION Checking the low pressure fuel supply circuit: C2, C3 (DV4TD) Checking the low pressure fuel supply circuit: C3 (DV4ATD4) Checking the low pressure fuel supply circuit: C2, C3 (DV6ATD4) Checking the turbo pressure: C2, C3 (DV4TD) Checking the turbo pressure: C3 (DV6ATD4) Checking the air supply circuit: C2, C3 (DV4ATED4) Checking the air supply circuit: C2, C3 Checking the air supply circuit: C3 Checking the exhaust gas recycling circuit: C2, C3 (DV4TD) IGNITION Sparking plugs 144 CLUTCH-GEARBOX-TRANSMISSION Clutch specifications: C2 Clutch specifications: C3, C3 Pluriel Gearbox specifications Tightening torques: MA gearbox 137 138 139 140 141 142 143 Recommendations - precautions: MA Tightening torques MA piloted g'box Tightening torques: BE4/5 reinforced Tightening torques: BE4/5 gearbox MA gearbox controls MA gearbox: checks and adjustments BE4/5 gearbox controls BE4/5 gearbox: checks/adjustments AL4: recommendations - precautions Tightening torques: AL4 gearbox AL4 gearbox controls Drain - refill: AL4 gearbox Gearbox - driveshafts 146 147 152 - 155 156 - 157 158 - 161 162 - 163 164 - 165 166 - 168 169 170 - 171 172 173 - 174 175 - 178 179 - 181 182 - 185 186 - 188 189
135 136
CONTENTS
AXLES - SUSPENSION - STEERING Axle geometry: C2 Tightening torques: front axle: C2 Tightening torques: rear axle: C2 Tightening torques: suspension: C2 Tightening torques: power steering C2 Setting the steering rack mid-point: C2 Axle geometry: C3 Axle geometry: C3 Pluriel Tightening torques: front axle: C3, C3 Pluriel Tightening torques: rear axle: C3, C3 Pluriel Tightening torques: suspension: C3, C3 Pluriel Tightening torques: power steering: C3, C3 Pluriel Setting the steering rack mid-point: C2, C3 Pluriel 190 - 193 194 195 196 197 - 198 200 201 - 205 206 - 208 209 210 211 - 213 214 - 215 217 BRAKES Brake specifications: C2 Adjusting the handbrake: C2 Filling, bleeding the brakes: C2 Brake specifications: C3 Brake specifications: C3 Pluriel Adjusting the handbrake: C3, C3 Pluriel Filling, bleeding the brakes: C3, C3 Pluriel AIR CONDITIONING R134.a: quantities Special features of aircon circuit Pollen filter: C2 Pollen filter: C3, C3 Pluriel Filtering and drying cartridge: C2, C3, C3 Pluriel Compressor lubricant Checking the efficiency of the circuit Aircon circuit: all Types: C2 244 245 246 247 248 - 249 250 - 251 252 - 260 261 218 - 223 224 - 225 226 - 228 229 - 233 234 - 238 239 - 240 241 - 243 Aircon circuit: all Types: C3, C3 Pluriel 262
IDENTIFICATION OF VEHICLES
C2
A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the LH centre pillar). D - Tyre pressures and tyre type (on the LH centre pillar). E - Serial number on bodywork. F - Gearbox ident. reference - Factory serial no. G - Engine legislation type - Factory serial no. GENERAL
E1AP0C3D
IDENTIFICATION OF VEHICLES
Type approval Structure J M HFX C /IF Family (1) Family (1) Bodywork (2) Engine (3) Version (4) Variant (5) Version (4) Depollution levels L5 US Others 83/87 C P V F R W H S X J N L T Y
JM HFXC/IF
C2 Bodywork (2) 3-door saloon not convertible from van 3-door saloon (4 seater) Engine (3) 1.1i TU1JP 1.4i TU3JP 1.6i 16V TU5JP4 1.6i 16V TU5JP4S 1.4 HDi DV4TD 1.4 HDi DV4TD
Manual 5-speed gearbox Manual 4-speed gearbox Manual 6-speed gearbox Automatic 6-speed gearbox Axle and/or gearbox gears Other possible combinations No gearbox
L3 W3 A
L4 B E G D K M
K K' 5 6
Alcohol L3/L4 L5 8 1 9 2 3 U 0 4
GENERAL
Z Variants (5) T AD SF IF P D (car or van not convertible from van) GPL (cylindrical tank) S 2 TD (convertible from van) GL (ring-shaped tank)
Entreprise convertible Integral alternator-starter (ADIN) Without FAP Fiscal incentives Piloted manual gearbox Downgraded depollution LPG dual fuel STT2 (stop and start)
IDENTIFICATION OF VEHICLES
C3
A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). GENERAL C - AS/RP No. and RP paint code (on the front pillar on driver's side). D - Tyre pressures and tyre type (on the front pillar on driver's side). E - Serial number on bodywork. F - Gearbox ident. reference - Factory serial no. G - Engine legislation type - Factory serial no.
E1AP09HD
IDENTIFICATION OF VEHICLES
Type approval Structure F Family (1) C Bodywork (2) FC HFXC/IF HFX Engine (3) C Version (4) /IF Variant (5) Family (1) F C3 Bodywork (2) 5-door saloon C (5-seater) Sport or leisure L (if different from base C) 5-door saloon not R convertible from van 5-door saloon T (if different from base N) Version (4) Depollution levels L5 US Others 83/87 C P V F R W H S X L T Y N U Z
Manual 5-speed gearbox Manual 4-speed gearbox Manual 6-speed gearbox Axle and/or gearbox gears Other possible combinations No gearbox
L3 W3 A D J
L4 B E G K M
K K' 5 6 7
Alcohol L3/L4 L5 8 1 9 2 3 0 4
GENERAL
IDENTIFICATION OF VEHICLES
Type approval (continued) HFX KFV KFU NFU N6A 8HX 8HZ 8HY 9HZ Engine (3) 1.1i TU1JP-TU1A 1.4i TU3JP-TU3A 1.4i 16V ET3JA 1.6i 16V TU5JP4 1.6i 16V TU5JP4 TR 1.4 HDi DV4TD 1.4 HDi DV4TD 1.4 16V HDi DV4TED4 DV6ATED4 1.6 16V HDi FAP Variants (5) Entreprise convertible Integral alternator-starter (ADIN) Without FAP Fiscal incentives Piloted manual gearbox Downgraded depollution LPG dual fuel STT2 (stop and start) Flex Fuel T AD SF IF P GENERAL D (car or van not convertible) GPL (cylindrical tank) S FF TD (van convertible) GL (ring-shaped tank)
C3 Pluriel
IDENTIFICATION OF VEHICLES
A - Cold stamp (cold stamp engraved on the bodywork). B - Manufacturer's name plate (on the LH centre pillar). C - AS/RP No. and RP paint code (on the front pillar on driver's side). D - Tyre pressures and tyre type (on the front pillar on driver's side). E - Serial number on bodywork. F - Gearbox ident. reference - Factory serial no. G - Engine legislation type - Factory serial no. GENERAL
E1AP0B2D
IDENTIFICATION OF VEHICLES
Type approval Structure H Family (1) N Bodywork (2) HN KFVC/IF KFV Engine (3) C Version (4) /IF Variant (5) Family (1) H C3 Pluriel Bodywork (2) B Cabriolet Engine (3) 1.4i 1.6i 16V 1.4 HDi 1.4 HDi Version (4) Depollution levels L5 US Others 83/87 C P V F R W H S X J N L T Y Z Variants (5) TU3JP TU5JP4 DV4TD DV4TD Entreprise convertible Integral alternator-starter (ADIN) Without FAP Fiscal incentives Piloted manual gearbox Downgraded depollution LPG dual fuel STT2 (stop and start) 7 D (Car or van not convertible from) GPL (cylindrical tank) S T AD SF IF P TD (van convertible) GL (ring-shaped tank)
GENERAL
Manual 5-speed gearbox Manual 4-speed gearbox Manual 6-speed gearbox Automatic 6-speed gearbox Axle and/or gearbox gears Other possible combinations No gearbox
L3 W3 A
L4 B E G D K M
K K' 5 6
Alcohol L3/L4 L5 8 1 9 2 3 U 0 4
C2 - C3
IMPERATIVE: All these operations are to be performed following a reconnection of the battery. Antiscanning function. It is necessary to wait 1 minute after the battery has been disconnected in order to be able to start the vehicle. Tailgate. The opening of the tailgate is deactivated on reconnection of the battery. Perform locking/unlocking to activate the opening of the tailgate. GENERAL Overspeed check. The vehicle's overspeed values have to be re-initialised. The button on the wiper stalk (multifunction display B or C) or the button on the dashboard (multifunction display A or clock) operates the following functions: - Activation of the vehicle's overspeed function. - Programming of the overspeed alert. Electric windows. It may be necessary to re-initialise the sequential and anti-pinch functions. NOTE: If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise. Open the window fully. Action and release the window switch until the window is completely closed. This operation has to be carried out on each electric window.
C2
GENERAL
ESSENTIAL: Systematically check the oil level using the oil dipstick. 10
C2
Diesel
TU5JP4
RPO 9884
RPO
HFX
NFS
8HZ GENERAL
2 2 0,15 0,7 Litre version with front calipers 48 / rear drums 0,8 Litre version with front calipers 54 / rear discs 7 40 5,6 45
ESSENTIAL: Systematically check the oil level using the oil dipstick.
11
C3
Petrol TU1JP TU3JP ET3J4
1.1i
1.4i BVA
1.4i 16V
1.6i 16V
GENERAL
Engine type Engine with filter change Between min. and max. 5-speed gearbox Automatic gearbox Braking circuit Cooling system Fuel tank capacity
HFX 3 1,5 2
KFV
ESSENTIAL: Systematically check the oil level using the oil dipstick. (1) = The gearbox is lubricated for life (for your information, the TOTAL capacity is 5,85 litres, after draining: 3 litres). 12
C3 PLURIEL
ESSENTIAL: Systematically check the oil level using the oil dipstick.
13
GENERAL
15
GENERAL
GENERAL
(*) It is essential not to use engine oils respecting these norms for XU10J4RS, SOFIM 2.8 TDi and SOFIM 2.8 HDi engines, HDi engines with particle filter EW10A, EW12J4, DV4TED4.
16
Oils specifically for diesel engines: S.A.E. norms TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 10W40 15W50 ACEA norms B3 API norms GENERAL CF
(*) Blended oils for all engines giving fuel economy. Oils for petrol, diesel and dual fuel petrol/LPG engines: S.A.E. norms TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 10W40 0W40 15W50 17 A3 SL ACEA norms API norms
GENERAL
EW10J4S (CITRON C4) Petrol engines EW12J4 (CITRON C8 2.2i 16V) EW10A (CITRON C4 and C5) Other petrol engines HDi engines with FAP (*) Diesel engines Other HDi engines SOFIM 2.8 HDi and 2.8 TDi (RELAY) DV4 TED4 (C3 1.6 16V HDi) Indirect injection diesel engines
X X X X X X
X X X X X X X X
(*) Do not use this oil in cold climatic conditions (temperature less than - 20C). See the table below for the choice of TOTAL engine oil grades to be used according to the climatic conditions in the country of marketing. 18
E4AP006D
19
GENERAL
Metropolitan FRANCE New Caledonia Guadeloupe Saint martin Reunion Martinique Guyana Tahiti Mauritius Mayotte
9000 5W40
Germany Austria Belgium Bosnia Bulgaria Cyprus Croatia (*) = Blended oils for all engines, giving fuel economy. 21
Denmark GENERAL Spain Estonia Finland Great Britain Greece Holland (*) = Blended oils for all engines, giving fuel economy. 22 9000 5W40 FUTUR1 9000 5W30 (*)
7000 10W40
7000 10W40 7000 10W40 7000 15W40 7000 10W40 9000 0W40
Hungary Italy Ireland Iceland Latvia Lithuania Macedonia (*) = Blended oils for all engines, giving fuel economy. 23 9000 5W40 FUTUR 9000 5W30 (*)
7000 10W40
7000 10W40
Malta GENERAL Moldavia Norway Poland Portugal Slovakia Czech Republic (*) = Blended oils for all engines, giving fuel economy. 24
Romania Russia Slovenia Sweden Switzerland Turkey (*) = Blended oils for all engines, giving fuel economy. 25 9000 5W40 FUTUR 9000 5W30 (*)
GENERAL
7000 10W40
TOTAL QUARTZ Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines
Algeria, South Africa, Ivory Coast, Egypt, Gabon, Ghana, Kenya, Madagascar, Morocco, Nigeria, Senegal, Tunisia (*) = Blended oils for all engines, giving fuel economy.
9000 5W40
7000 10W40
27
GENERAL
7000 10W40
Argentina GENERAL Brazil Chile Cuba Mexico Paraguay Uruguay 28 9000 5W40 7000 10W40 7000 15W50 7000 10W40
7000 15W50 India - Indonesia Japan Malaysia 9000 5W40 Pakistan (*) = Blended oils for all engines, giving fuel economy. 29 7000 15W50 9000 5W40 9000 5W40 FUTUR 9000 5W30 (*)
Philippines 7000 15W50 Singapore Taiwan Thailand 7000 15W50 Vietnam 9000 5W40 7000 10W40 7000 15W50 7000 10W40 GENERAL
30
31
GENERAL
32
Power steering
ENGINE COOLANT FLUID Packs 2 Litres All countries CITRON fluid Protection: -35C 5 Litres 20 Litres 210 Litres 33 CITRON Part No. GLYSANTIN G33 9979 70 9979 71 9979 76 9979 77 REVKOGEL 2000 9979 72 9979 73 9979 74 9979 75
WARNING: TOTAL FLUIDE LDS fluid cannot be blended with TOTAL LHM PLUS WARNING: CITRON C5: Use exclusively TOTAL FLUIDE LDS suspension fluid. All countries 34 TOTAL HYDRAURINCAGE
Packs Concentrated: 250 ml All countries Fluid ready to use 1 Litre 5 Litres 9980 33 9980 06 9980 05
CITRON Part No. ZC 9875 953U ZC 9875 784U ZC 9885 077U ZC 9875 279U GENERAL 9980 56
Norms NLGI 2
All countries
35
GENERAL
36
ENGINE SPECIFICATIONS
Petrol engines All Types
1.1i
1.4i
1.4i 16V
1.6i 16V
Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC (KW - rpm) Torque ISO or EEC (m.daN - rpm)
KFU
NFS
37
ENGINE
ENGINE Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC (KW - rpm) Torque ISO or EEC (m.daN - rpm) 15-1750 8HX
ENGINE SPECIFICATIONS
Diesel engines All Types
1.4 HDi
8HY
38
C2
B1BP2Y3P
39
ENGINE
ENGINE
C2
Engines
Accessories drive pulley Pinion fixing on crankshaft Tightening Angular tightening Sump Timing belt tensioner roller Accessories belt guide roller Alternator support Alternator TU1JP - TU3JP Pre-tightening Tightening Alternatorr TU5JP4 Pre-tightening Tightening Aircon compressor support Aircon compressor
2,5 0,2 4 0,4 45 4 Cylinder block 0,8 0,2 2,1 0,2 2,5 0,2 2,5 0,2 1 3,7 0,3 1 4 ,04 2,2 0,2 2,3 0,2
40
C2
41
ENGINE
ENGINE
C2
Engines
Coolant pump
1,6 0,2
42
C2
: 6 0,6 : 6 0,6 : 6 0,6 : 6 0,6 : 3 0,3 : 6 0,6 : 5,5 0,5 : 5,7 0,9
B1BP2Y1P
43
ENGINE
ENGINE
C2
Engines Bearing cap fixing screws Pre-tightening Slackening Tightening Angular tightening Con rod screws Tightening Angular tightening Accessories drive pulley Pre-tightening Angular tightening Sump Timing belt guide roller Timing belt tensioner roller
44
C2
45
ENGINE
ENGINE
C2
Engines Oil pump assembly Pre-tightening Tightening Coolant/oil heat exchanger
Spherical-base screws for diesel injection fixing fork Fuel high pressure common injection rail on engine block Unions on fuel high pressure common injection rail Diesel injection pump on support Union on diesel injector Diesel injection pump pulley Union on diesel high pressure pump Coolant pump Pre-tightening Tightening Coolant outlet housing Pre-tightening Tightening
C3 - C3 PLURIEL
C3 A = HFX - KFV B = NFU RH engine support (1) : 4,5 0,4 (2) : 6,1 0,6 (3) : 4,5 0,4 Torque reaction rod (4) : 6 0,6 (5) : 6 0,6 LH engine support on gearbox (6) : 3 0,3 (7) : 6 0,6 (8) : 5,5 0,5
B1BP2NEP
C3 Pluriel A = KFV B = NFU RH engine support (1) : 6 0,4 (2) : 6 0,6 (3) : 4,5 0,4 Torque reaction rod (4) : 6 0,6 (5) : 6 0,6 LH engine support on gearbox (6) : 3 0,3 (7) : 6 0,6 (8) : 5,5 0,5
47
ENGINE
ENGINE
C3
Engines Accessories drive pulley Pinion fixing on crankshaft Sump Timing belt tensioner roller Accessories belt tensioner roller Alternator support fixing Alternator fixing on support Coolant outlet housing Camshaft bearing cap Tightening Angular tightening Inlet manifold Exhaust manifold Valve rockers adjusting screw Sparking plugs Camshaft pulley screw
C3
49
ENGINE
ENGINE
C3
LH engine support on gearbox (5) (6) (7) : 3 0,3 : 6 0,6 : 5,5 0,5
B1BP2ZBP
50
C3
ENGINE
ENGINE
C3
Exhaust manifold Sparking plugs VVT pulley cap VVT control electrovalve VVT inlet camshaft pulley screw Pre-tightening Tightening Exhaust camshaft pulley screw
6,7 0,6 (coat the screws with LOCTITE FRENETANCH) 2 0,2 Lubrication circuit 2 0,2 0,9 0,1 Cooling circuit
C3 - C3 PLURIEL
LH engine support on gearbox (5) (6) (7) : 5,4 0,5 : 6 0,6 : 5,5 0,5
B1BP2LJP
53
ENGINE
ENGINE
C3 - C3 PLURIEL
8HZ
54
C3 - C3 PLURIEL
8HZ
1,7 75 5
ENGINE
ENGINE
C3 - C3 PLURIEL
Engines
Spherical-base screws for diesel injection fixing fork Fuel high pressure common injection rail on engine block Unions on fuel high pressure common injection rail Pre-tightening Tightening Diesel injection pump on support Union on diesel injecton Diesel injection pump pulley Union on diesel high pressure pump
0,3 0,1 2 0,2 1,7 0,2 2,25 0,2 2,25 0,2 5 0,5 2,25 0,2 Cooling circuit
Coolant pump Pre-tightening Tightening Coolant outlet housing Pre-tightening Tightening 56 0,3 0,06 0,7 0,08 0,3 0,06 1 0,1
C3
LH upper engine support Screw (7) Screw (8) : 6 0,6 : 5,5 0,5
B1BP2MNP
57
ENGINE
ENGINE
C3
Engine
Bearing cap fixing screw Tightening Angular tightening Crankshaft pullet hub Tightening Angular tightening Oil sump Timing belt tensioner roller Timing belt guide roller Timing belt guide roller support Camshaft bearing cap cover Inlet manifold Exhaust manifold Cylinder head cover Camshaft pinion Fuel high pressure pump pinion 58
3 0,3 140 1,4 3 0,3 180 5 Cylinder block 1 0,1 4 0,4 2,5 0,2 Cylinder head 1 0,1 2,5 0,2 Screws (M6) to 1 0,2 4,3 0,4 5 0,5
C3
ENGINE
ENGINE
C3
LH upper engine support Screw (7) Screw (8) : 6 0,6 : 5,5 0,5
B1BP2MNP
60
B1BP39YP
B1DP1D7D
61
ENGINE
ENGINE
B1BP39YP
4 5 6 7 8
0,5 0,1 1 0,1 1 0,1 2 0,2 4 0,5 260 5 1,8 0,2 0,3 0,1 0,7 0,1
B1DP05BC
62
B1BP39YP
63
ENGINE
ENGINE
B1DP1LKP
14
15
16
B1CP0GKC
64
17
18 19
20
B1DP1LKP
65
ENGINE
ENGINE
B1DP1LLD
66
B1DP1LMD
67
ENGINE
ENGINE
B1EP1HQD
68
39
40 41 42 43
B1HP22SD
69
ENGINE
ENGINE
B1HP22SD
70
D1AP02NC
71
ENGINE
ENGINE
D1AP02PC
D1AP02QD
72
HFX - KFV
NFU
122
KFU
B1DP05BC
119
ENGINE
ENGINE
149
9HX
B1DP1CLC
147
All Types ! !
4099-T (C.TRONIC.105)
75
ENGINE
JP
HFX X
JP4
NFU X
JP4S
NFS X 8HX X
TD
80 to 81
82 to 83
84 to 86
80 to 81
87 to 88
89
90 to 91
76
Tools. - Belt tension measuring instrument: 4122 - T (C.TRONIC 105.5). WARNING: If using tool 4099-T (C.TRONIC 105) Essential. - Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness). - 2 / The belt is correctly engaged in the grooves of the various pulleys.
77
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1BP2LSC
Slacken: - Screw (2). - Screw (3). - Tensioning screw (1). Push the alternator back towards the engine. Remove the belt.
B1BP2LTC
78
C2 - C3 - C3 PLURIEL
B1BP10VC
B1BP10XC
79
ENGINE
ENGINE
C3
Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove the front RH wheel and the front RH splash-shield, using tool [1].
B1BP2LSC
Vehicle without air conditioning. Removing. Slacken the tension, screw (2), screw (3) and screw (1). Push back the alternator towards the engine. Remove the auxiliary equipment drive belt. Refitting. Refit the auxiliary equipment drive belt. Respect the following sequence: - Crankshaft pinion, alternator pulley. - Position tool [2] on the belt. Tighten the screw (1) to tension the belt to 55 3 SEEM units. - Tighten screw (3), screw (2). - Remove tool [2]. - Complete the refitting in the opposite order to removal.
B1BP2LTC
80
C3
Refit the auxiliary equipment drive belt. Respect the following sequence: - Crankshaft pinion, aircon compressor pulley, alternator pulley guide roller and guide roller. - Position tool [2] on the belt. Tighten the screw (5) to tension the belt to 120 3 SEEM units. - Tighten screw (4), screw (6). - Remove tool [2]. - Complete the refitting in the opposite order to removal.
B1BP10XC
81
ENGINE
ENGINE
C3
IMPERATIVE: Respect the precautions to be taken prior to any operation. Checking the stop and start accessories belt.
Checking the belt extension. Disconnect the battery. Using a vernier gauge, measure the extension of the tensioner. The length X should be between 77.6 mm and 85.6 mm. Replace the accessories belt if the extension value is greater than 85.6 mm.
Visual checking of the belt. Remove the accessories belt, using tool [1] (see corresponding operation). Carefully twist the belt to check that there is no cracking or splitting, whether on the back of the belt or in the notches.
B1EP1J6C
82
C3
B1EP1J7C
83
ENGINE
ENGINE
C3
B1EP1J8C
B1BP3BEC
C2 - C3 - C3 PLURIEL
Removing. Disconnect the battery negative cable. Raise and support the vehicle, wheels hanging. Remove the front RH wheel. Move aside the splash-shield, using tool [1]. IMPERATIVE: In the case of belt re-use, mark the direction of rotation of the belt. If the index on the tensioner roller is outside the marks, change the auxiliary equipment drive belt. Remove: - The alternator (1). - The aircon compressor (2). Detension the auxiliary belt tensioner roller, using tool [2]. Position the peg [3]. Remove the auxiliary drive belt.
B1BP2MJD B1BP2MKC
85
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1EP18UD
86
C3
B1BP2MYD
Removing. Pivot the tensioner roller support (1) (clockwise), using tools [1a] and [1b] at a. Remove the belt. Immobilise the support (1) of the tensioner roller, using tool [2]. Remove the auxiliary drive belt (2). IMPERATIVE: Ensure that the tensioner rollers turn freely (no play, no tight spot). Refitting. Refit the belt. Move the tool [1] on the tensioner roller to remove the peg [2]. ESSENTIAL: Make sure that the belt is correctly positioned in the various pulley grooves.
B1BP2MZC
87
ENGINE
ENGINE
B1EP18UD B1BP3ACD
C3
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Markings on the dynamic tensioner roller. a position maximum wear of the auxiliaries drive belt. b Nominal position. Removing. WARNING: Mark the direction of fitting of the auxiliaries drive belt in the case of re-use of the belt. Compress the dynamic tensioner roller (1) by acting at c (clockwise), using tool [1]. Peg using tool [2] at d. Keep the dynamic tensioner roller (1) compressed and remove the auxiliaries drive belt.
88
C3
IMPERATIVE: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys.
B1EP18UD
Refit: - The front RH wheel. - The sound-deadening under the engine. - Reconnect the battery. IMPERATIVE: Carry out the operations that are necessary following a reconnection of the battery (see corresponding operation).
B1BP3ACD
89
ENGINE
JP
HFX X
JP4
NFU X
JP4S
NFS X 8HX X
TD
94 to 103
104 to 109
94 to 103
110 to 117
90
Recommendations.
IMPERATIVE: After any repair involving removal of the timing belt, systematically replace: - The timing belt, - The tensioner roller fixing nut.
91
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
: : : : : : :
92
C2 - C3 - C3 PLURIEL
B1BP2MAC
B1EP18MC
B1BP2MBC
93
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
94
C2 - C3 - C3 PLURIEL
B1BP2MEC
B1EP18NC
95
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1BP2MFC
B1BP2MBC
B1EP18MC
96
C2 - C3 - C3 PLURIEL
Turn the tensioner roller so as to be able to position the tool [4], with the aid of an Allen key placed at a. Turn the tensioner roller towards the right to bring it to the index c in position b. Peg the tensioner roller in this position in order to slacken the timing belt to the maximum. IMPERATIVE: Never make the dynamic tensioner roller turn by a complete rotation. Remove the timing belt (8). Check that the rollers (9) and (10) turn freely (no tight spot).
B1EP18PC
B1EP18QC
97
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1EP18QC
98
C2 - C3 - C3 PLURIEL
B1EP18RC
Engines: HFX - KFV. Refitting. NOTE: Check that the pegs [1] and [2] are in place. WARNING: Respect the direction of fitting of the timing belt, the arrows d indicate the direction of rotation of the crankshaft. Refit the timing belt. Position the timing belt, belt e well tensioned, in the following order: - Crankshaft pinion, hold the belt using tool [5]. - Camshaft pulley. - Coolant pump pulley. - Tensioner roller. Remove the tools [1], [2]. Engines: NFU - NFS. Fit the timing belt in position in the following order: - Inlet camshaft pulley. - Exhaust camshaft pulley. - Guide roller. - Crankshaft pulley. Position tool [5]. - Coolant pump pulley. - Dynamic tensioner roller. Remove the tools [1], [3] and [5]. 99
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1EP18SD
100
C2 - C3 - C3 PLURIEL
Engines: HFX - KFV - NFU - NFS
Slacken the nut while maintaining the position of the tensioner roller, with the aid of a hexagonal spanner at a. Next bring the index c to its adjusting position a. The index c should not go beyond the notch g. WARNING: The index c must not go beyond the notch g. If it should do this, restart the timing belt tensioning operation. Hold the tensioner roller (7) in this position, with the aid of a hexagonal spanner. Tighten the tensioner roller fixing nut to: 2 0.2 m.daN. (HFX - KFV engines). 2.2 0.2 m.daN. (NFU - NFS engines). IMPERATIVE: The tensioner roller must not rotate during the tightening of its fixing. If it does, restart the timing belt tensioning operation. Complete the refitting.
B1EP18TD
101
ENGINE
ENGINE
C3
B1BP2ZJD
102
C3
Position the tools [3] and [2]. Peg the flywheel, using tool [1]. NOTE: If the setting is not correct, recommence the operation. Remove the pegs [2] and [3]. Refit: - The oil filter. - The timing cover (1). - The engine cover. Reconnect the battery. Lower the vehicle. Perform the operations that are necessary following a reconnection of the battery.
B1BP2ZTC
B1BP2MBC
103
ENGINE
ENGINE
C3
Removing. Raise and support the vehicle, front wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The engine cover. - The accessories drive belt (see corresponding operation). - The crankshaft pulley. - The oil filter. Remove the upper timing cover (1).
B1BP2ZJD
104
C3
Rotate the engine by means of the crankshaft pinion screw (2) (clockwise) to bring it to the pegging position. Peg the flywheel, using tool [1]. Position the tools [3] and [4]. Position the tool [2]. Support the engine. Remove the screws (3). The upper RH engine support.
B1BP2MCC B1BP2MBC
B1BP2ZTC
B1BP2ZUC
105
ENGINE
ENGINE
C3
B1CP0F1D
Fit the (new) timing belt, in the following sequence: - Inlet camshaft pulley. - Exhaust camshaft pulley. - Guide roller. - Crankshaft pulley. - Position the tool [5]. - Coolant pump pulley. - Dynamic tensioner roller. - Remove tools [3], [4] and [5].
B1CP0F2D
106
C3
B1EP1DTC
Overtensioning the belt. Position a: Tensioner roller in slackened position. Position b: Tensioner roller in normal position. Position c: Tensioner roller in overtensioned position. Turn the tensioner roller (8) using an allen spanner at e. Position the index d in position c, tension the belt to the maximum indicated. Tighten the fixing nut of the tensioner roller to 2,1 0,2 m.daN. Rotate the crankshaft by four turns (normal direction of rotation). IMPERATIVE: Never turn the crankshaft backwards. Make sure the timing setting is correct by refitting the pegs [1], [3] and [4]. Remove the pegs [1], [3] and [4]. Adjusting the tension of the belt. Slacken the nut, holding the position of the tensioner roller, by means of an allen spanner at e. Then bring the index d to its adjustment position b. WARNING: The index d should not go past the notch b. If it should do so, repeat the operation to tension the timing belt. Maintain the tensioner roller (8) in this position, using the allen spanner. Tighten the fixing nut of the tensioner roller to 2,1 0,2 m.daN. IMPERATIVE: The tensioner roller should not turn during the tightening of its fixing. If it should do so, repeat the operation to tension the timing belt. Refitting. Complete the refitting in the opposite order to removal. 107
B1EP1DUC
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
: : : : :
Preliminary operations. Remove: - The front RH wheel. - The front RH splash-shield, using tool [1]. - The clips of the electrical harness on the upper timing cover. - The accessories belt, using tool [2] (see corresponding operation). Check ing the setting. Disconnect the battery negative cable. Remove the upper timing cover (1). Rotate the engine using the screw (2) of the crankshaft pulley. NOTE: The locking hole is located under the crankshaft bearing cap cover. Undo the screw (2). Detension the auxiliary drive belt dynamic tensioner roller, using tool [2].
B1BP2LXC
108
C2 - C3 - C3 PLURIEL
109
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
Setting the timing.
Remove the upper timing cover (1). Rotate the engine by means of the crankshaft screw (2). NOTE: The pegging hole is located under the crankshaft bearing cap cover. Peg the engine flywheel, using tool [3]. Remove the lower timing cover (3). Uncouple the exhaust line from the manifold. IMPERATIVE: Uncouple the exhaust line in order to avoid damaging the front flexible pipe. Twisting, pulling and bending the front flexible pipe reduces its life. Remove: - The engine speed sensor (6). - The belt retaining stop (5). - The screw (2). - The crankshaft pinion (4) (with its magnetic track a). IMPERATIVE: The magnetic track should show no signs of damage and should not be approached by any other source of magnetism. Should this not be adhered to, it is essential to replace the crankshaft pinion. Refit the screw (2).
B1BP2LXC
B1EP18GC
110
C2 - C3 - C3 PLURIEL
B1JP03SC
B1EP18DC
B1EP195C
B1BP2LYC
111
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
Check the condition of the seals at the camshaft and at the crankshaft pinion.
B1EP18HC
112
C2 - C3 - C3 PLURIEL
Engines: 8HX - 8HZ
Position the timing belt (10) observing the following sequence: - Crankshaft pinion (4). - Guide roller (12). - Camshaft pulley (11) (check that the belt is held correctly against the roller). - Coolant pump pinion (13). - Fuel high pressure pump pulley (15). - Tensioner roller (14).
B1EP18JD
113
ENGINE
ENGINE
C2 - C3 - C3 PLURIEL
B1EP18KC
114
C2 - C3 - C3 PLURIEL
- The intermediate RH engine support, tighten the screws (16) to 5,5 0,5 m.daN. - The RH engine support, tighten the screws (17) to 4,5 0,4 m.daN. - The bottom timing cover (3). Immobilise the engine flywheel, using tool [3]. Remove the screw (2). Refit the accessories drive pulley and tighten to: Pre-tighten to : 3 0,3 m.daN. Angular tighten to : 180 1,8. Remove tool [3]. Refit: - The top cover (1). - The accessories belt (see corresponding operation). - The exhaust line (see corresponding operation). - The front RH splash-shield. - The front RH wheel.
B1EP18LC B1BP2LZC
115
ENGINE
ENGINE
C3
Preliminary operations. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories belt (see corresponding operation). Uncouple: - The supply unions (1). - The air/air heat exchanger inlet/outlet pipes (3). - The exhaust line (at the flexible pipe). Disconnect the connector (2). Support the engine by means of a roller jack equipped with a chock. Remove the engine supports (4) and (5).
B1BP2N0C
116
C3
117
ENGINE
ENGINE
C3
B1EP18YD
118
C3
If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Refitting. Refit the tool [1] at a. Remove the screw (8). Refit: - The upper timing cover (11). - The lower timing cover (10). - The accessories drive pulley (9). - The screw (8). Tightening: - Screw (8): Pre-tighten to Angular tightening Remove the tool [1].
B1EP18ZC
119
ENGINE
ENGINE
C3
B1BP2N0C
120
C3
Perform the preliminary operations for checking the timing up to removing tool [1] at a for immobiling the engine flywheel. Refit screw (8). Rotate the crankshaft to bring the camshaft towards its pegging point. Peg the camshaft, using tool [2] (oil the pegs). WARNING: Do not press or damage the track which is the target for the engine speed sensor (14). Peg the crankshaft at b, using tool [3]. Remove: - The timing protector (13). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, keeping it slack with the aid of a hexagonal spanner at c. Detension the belt by pivoting the tensioner roller (clockwise). Remove the timing belt, commencing with the coolant pump pinion. Peg the pulley (15), using a 5 mm diameter peg at d.
B1EP18VD
121
ENGINE
ENGINE
C3
B1EP18WD
122
C3
Reposition the timing belt, belt at e well tensioned, in the following order: - Guide roller (17). - Camshaft pulley (16). - Fuel high pressure pump pulley (15). - Coolant pump pinion (18). - Tensioner roller (19). Remove the 5 mm diameter peg at d. Adjusting the fitting tension of the belt. Action the tensioner roller (19) to align the marks f and g, avoiding detensioning the timing belt, with the aid of a male hexagonal spanner at c. If this is not successful, repeat the operation to tension the belt. Hold the tensioner roller in position (19). Tighten the tensioner roller, tightening to 3,7 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks f and g should be correct). Remove tools [2] and [3]. Turn the crankshaft six rotations (clockwise).
B1EP18XC
123
ENGINE
ENGINE
C3
B1EP18XC
C3
B1BP3AMC
B1BP2N1C
Tools. [1] Flywheel setting peg : (-).0194.C [2] Camshaft setting peg : (-).0194.B [3] Crankshaft setting peg : (-).0194.A IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Checking the timing. Raise and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories drive belt (see corresponding operation). Remove the engine supports (4) and (5). Uncouple: - The fuel supply unions (1). - The air/air heat exchanger inlet (2) and outlet (3) pipes. - The exhaust line (at the flexible pipe). Support the engine with a roller jack equipped with a block. Turn the engine in its normal direction of rotation. Peg the flywheel, using the peg [1] (at "a"). 125
ENGINE
ENGINE
B1BP2N2C B1EP1HSD
C3
126
C3
Note: The index c of the dynamic tensioner roller should be centred in the interval d. Check the correct positioning of the index c. If it is not correct, repeat the operation to tension the timing belt (see corresponding operation). Remove tools [2] and [3]. Refitting. Proceed in reverse order. Tightening torques. Method for tightening the screw (8): - Pre-tightening : 3 0,3 m.daN. - Angular tightening : 180 5. Engine support (7) tighten to Engine support (4) tighten to Engine support (5) tighten to Exhaust line clip: tighten to Front RH wheel: tighten to : : : : : 1,5 0,4 m.daN. 6,1 0,6 m.daN. 6 0,6 m.daN. 2,5 0,3 m.daN. 9 1 m.daN.
IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery (see corresponding operation).
B1EP1HTC
127
ENGINE
ENGINE
C3
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engine versions. Checking the timing. Raise and support the vehicle, wheels hanging. Disconnect the battery. Remove: - The front RH wheel. - The front RH splash-shield. - The accessories drive belt (see corresponding operation). Remove the engine supports (4) and (5). Uncouple: - The fuel supply unions (1). - The air/air heat exchanger inlet (2) and outlet (3) pipes. - The exhaust line (at the flexible pipe). Support the engine with a roller jack equipped with a block. Turn the engine in its normal direction of rotation. Peg the flywheel, using the peg [1] (at "a"). 128
B1BP3AMC
B1BP2N1C
C3
B1BP2N2C
WARNING: Do not press or damage the track of the engine speed sensor target (14). Use tool [3] to peg the crankshaft at b. Remove: - The timing belt protector (13). - The engine speed sensor (14). Slacken the screw (12) of the tensioner roller, and keep it slackened using an allen spanner at c. Detension the timing belt by pivoting the tensioner roller (clockwise). Remove the timing belt, starting with the coolant pump pinion.
B1EP18VD
129
ENGINE
ENGINE
C3
B1EP18WD
130
C3
Act on the tensioner roller (19) to align the marks f and g, avoiding detensioning the timing belt, using an allen spanner at c. Should this fail, repeat the operation to tension the timing belt. Hold the tensioner roller (19). Tighten the tensioner roller fixing nut to 3,7 0,3 m.daN. Check the position of the tensioner roller (the alignment of the marks f and g should be correct). Remove tools [2] and [3]. Rotate the crankshaft six times clockwise. IMPERATIVE: Never rotate the engine backwards. WARNING: Do not touch or damage the track of the target of the engine speed sensor (14). Peg the crankshaft, using tool [3]. Check the position of the tensioner roller (the alignment of the marks f and g should be correct). If this is not the case, repeat the operation to tension the timing belt. Peg the camshaft pulley, using tool [2].
B1EP18XC
131
ENGINE
ENGINE
C3
ESSENTIAL: Should it not be possible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. If it is more, repeat the operation to position the timing belt (see corresponding operation).
Remove tools [2] and [3]. Refit tool [1] at a. Remove the screw (8). Refit: - The upper timing cover (11). - The lower timing cover (10). - The pulley (9). - The screw (8). Method for tightening the screw (8): - Pre-tighten to 3 0,3 m.daN. - Angular tighten 180 5. - Remove tool [1].
Refit: - The engine support (7), tighten to 5,7 0,9 m.daN. - The engine support (4), tighten to 6,1 0,8 m.daN. - The engine support (5), tighten to 6 0,6 m.daN. - The electrical harness (6). Disengage the jack from under the engine. Complete the refitting. IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery (see corresponding operation).
132
NOTE: The oil pressure should be checked with the engine hot, after the oil level has been checked.
133
ENGINE
ENGINE
Adjust
3 4 2 1 4 2 1 3
B1DP13QC
134
SPEEDOMETER
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates: - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed SD and the speed travelled ST, there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph CLUTCH GEARBOX TRANSMISSION Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph. The speed indicated by the speedometer may be influenced by: - The speedometer. - The tyres fitted to the vehicle. - The final drive ratio. - The speedometer drive ratio. Any of these components can be checked without removing them from the vehicle (see information note N 78-85 TT of 19 October 1978). NOTE: Before replacing the speedometer, check the conformity of the following points: - The tyres fitted to the vehicle. - The gearbox final drive ratio. - The speedometer drive ratio. 145
C2
TU1JP Engine type Gearbox Make Mechanism/type Clutch disc CLUTCH GEARBOX TRANSMISSION Ext./int. lining Disc lining type HFX BVM (*) MA 5/S VALEO 180 CP0 3400 11 R 10 180/127 TU3JP KFV BVM/BVMP (**) MA 5 N/L
CLUTCH SPECIFICATIONS
TU5JP4 NFU BVM/BVMP (**) MA 5 S/L LUK 200 P 3900 200 CPX 3850 200 P 3900 TU5JP4S NFS BVM (*) MA 5 S 8HX BVM/BVMP (**) MA 5/0 DV4TD 8HZ
200/134 408
(*) (**)
146
CLUTCH SPECIFICATIONS
TU1JP Engine type Gearbox Make Mechanism/type Clutch disc Ext./int. lining Disc lining type HFX MA/5 VALEO 180 CPO 3400 11 R 10 X 180/127 F408 200/134 810 DS 200/134 F 408 TU3JP KFV ET3J4 KFU MA/5S MAP SACHS 200 MF 3850 200 P 3900 TU5JP4 NFU MA/5N 8HX MA/5O LUK DV4TD 8HZ
C3 - C3 PLURIEL
DV4TED4 8HY BE4/5L DV6ATED4 9HX BE4R/5L
230 P 4700
235 P 4800
228/155
235/165 810 DS
147
C2 - C3 - C3 PLURIEL
CLUTCH SPECIFICATIONS
NOTE: All the clutches are push type with hydraulic control. Description. The declutch control has a declutch fork mounted on a ball-joint. (1) The ball-joint is screwed into the clutch casing (2) Declutch fork (3) Clutch casing (4) Bearing (5) Clutch plate
The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing. Tightening torques (m.daN). - Fixing of clutch plate / engine flywheel - Fixing of clutch control slave cylinder / clutch housing - Fixing of engine flywheel / crankshaft Pre-tightening Angular tightening
B2BP047C B2BP04QC
148
C3
2 0,2 6,7 0,6 1,7 0,2 70 5
B1DP1LXC
B1CP0H9C
149
C2 - C3 - C3 PLURIEL
IMPERATIVE: Do not use automatic bleeding equipment (risk of the brake fluid emulsifying in the hydraulic circuit).
Couple a transparent tube (5) on the bleed screw at c. Submerge the end of the tube (5) in the recipient containing the brake fluid, located below the level of the clutch slave cylinder. Use the transparent tube (5) to act as a siphon at b. WARNING: the end of the tube (5) must be submerged in the brake fluid. Open the bleed screw, at c.
150
C2 - C3 - C3 PLURIEL
Action the clutch pedal manually through its full travel: 7 times rapidly down and up. Allow the clutch pedal to come back up to its high position. Fill the brake fluid reservoir to the maximum of its capacity. Open the bleed screw at c. Action the clutch pedal manually through its entire travel: 7 times rapidly down and up. The last time, keep the clutch pedal fully down. Reclose the bleed screw, at c. If necessary, repeat the operation. Top up the brake fluid to the MAX. level of the brake fluid reservoir. Work the clutch vigorously 40 times. Start the engine. Apply the handbrake. Engage a gear. Check that the clutch starts to engage at a dimension (X) greater than or equal to 45 mm (the dimension (X) is given as a guide). Repeat the bleed operations if necessary.
C5FP0FQC
B2BP04YC
151
C2
C3 Pluriel
152
TU1JP
21x18
C3
TU3JP
21x18 None
153
None
155
C2 - C3 - C3 PLURIEL
Ref. 1 2
Gearbox casing
1,9 0,2
0,6 0,15
156
C2 - C3 - C3 PLURIEL
Number of screws 3 2,5 0,5 1 3,3 0,3 CLUTCH GEARBOX TRANSMISSION 3,3 0,3 Tightening 2,2 0,2
B2CP3SSD
157
C2 - C3
ESSENTIAL: Given the special features of the MA type piloted manual gearbox, observe the requirements detailed below. IMPERATIVE: Always disconnect the battery negative terminal before operating on the actuators. NOTE: After disconnecting the battery, never try to remove the clutch actuator on the vehicle before having checked that it is in the closed position (rod pushed in). IMPERATIVE: After Sales checks done with the engine running must be performed with Neutral engaged and the handbrake on (unless there is a clear mention otherwise in the repair procedures). IMPERATIVE: The areas of movement of the clutch fork and of the gear engagement lever must always be kept free during the actuator operating phases.
IMPERATIVE: When initialising the clutch actuator and/or gearbox actuator, do not allow any person to walk or stand in front of the vehicle. WARNING: When the engine is running, it is forbidden to perform repairs on the clutch and gearbox actuators on the vehicle (whether manually or using a diagnostic tool). WARNING: Each time the driver's door is opened and each time the igntion is switched on, the gearbox ECU prompts the initialising of the clutch and gearbox actuators (there is movement of the clutch fork and of the gear lever). WARNING: Whether the ignition is switched on or not, an action on the gear selector causes the clutch fork and the gear engagement lever to move on the gearbox.
158
C2 - C3
It is necessary to lift the front of the vehicle to tow it, after having positioned the gear lever in neutral. If there is a gearbox fault or malfunction, the vehicle can remain immobilised depending on the seriousness of the fault. CLUTCH GEARBOX TRANSMISSION If a gear is engaged, the conditions for immobilisation of the vehicle are: - Engine stopped (the engine should not be started). - The clutch is open (clutched). In these conditions are met, you can lift the front of the vehicle to tow it. If it should not be possibe to lift the front of the vehicle, there are ways to unblock it:
159
C2 - C3
Engaging of N, using a diagnostic tool. Preliminary operations: - Battery voltage higher than 12.5 volts. - Ignition switched on. - Connect the diagnostic tool to the vehicle's diagnostic socket. From the diagnostic tool menus, select: - DIAGNOSIS - MA type piloted manual gearbox. - Actuator test. - Gearbox actuator test. - Gear engagement test. - N (neutral). NOTE: The letter N should appear on the instrument panel. If not, see the following solution: - Engaging of N, without using a diagnostic tool.
160
C2 - C3
Engaging of N, without using a diagnostic tool (continued). Preliminary operation: - Disconnect the battery negative terminal. - Remove the air filter. CLUTCH GEARBOX TRANSMISSION - Use a 22 mm spanner. Use the spanner to lift the gear engagement lever the maximum possible until the axis A of the engagement lever is perpendicular to the axis B (mid point of the gear engagement lever). When this position is attained, position N is engaged.
B2CP3L8D
161
C2 - C3
162
C2 - C3
Tightening 2,2 0,2 0,8 0,2 2,5 0,5 3,3 0,3
B2CP3VTD
163
C3
164
C3
Tightening 5 0,5 1,7 0,2 1,25 0,2 2,2 0,2 1,25 0,2 3,5 0,3 CLUTCH GEARBOX TRANSMISSION
B2CP3BRD
165
C3
8 9 10 11
166
C3
Tightening 1,5 0,2 7 0,5 1,5 0,2 6,5 0,5 7,3 0,5, CLUTCH GEARBOX TRANSMISSION
B2CP3ZYD
167
C3
B2CP3ZZC
B2CP400C
168
C2 - C3 - C3 PLURIEL
B2CP3HXD
169
C2 - C3 - C3 PLURIEL
C2 Length D Gear engagement control cable (2) 1040 mm Length A Gear engagement control cable (3) 170 1149 mm Length C 815 mm Length B 800 mm Length D 1015 mm Length A 1093 mm
C2 - C3 - C3 PLURIEL
Adjustment.
WARNING: Do not use any tool to detach the ball-joints. The gear selection control and gear engagement control cables cannot be adjusted. To unlock the ball-joint, press at a then pull the ball-joint upwards. To release the sleeve stops, pull the needles b, in the direction of the arrow, then disengage the sleeve stops from their supports.
B2CP3J0D
B2CP3J1D
171
C3
172
C3
B2CP3J4C
Length A Gear engagement control cable (5) 907 mm Length D Gear engagement control cable (4) 173 965 mm
B2CP3J5D
C3
Adjustment. The gear selection control and gear engagement control cables cannot be adjusted.
To release the ball-joint, press at b then pull the ball-joint upwards. To release sleeve stops: - Press on the tabs of the clip (6) at a. - Disengage the sleeve stops from their supports.
174
C3
Before reconnecting a switch, check: - The condition of the various contacts (for deformation, corrosion etc.). - The presence and condition of the mechanical locking. When performing electrical checks: - The battery should be correctly charged. - Never use a voltage source higher than 16V. - Never use a test lamp. CLUTCH GEARBOX TRANSMISSION
Lubrication. The automatic gearbox is only lubricated when the engine is running.
175
C3
Repairs on mechanical components. Never place the gearbox on the ground without protection. In order to avoid breaking the input shaft ring, it is imperative that the converter retaining bracket should be in place when handling the gearbox. It is imperative to use the centring peg and the converter retaining bracket to couple the gearbox on the engine. After coupling the gearbox on the engine, remove the centring peg. CLUTCH GEARBOX TRANSMISSION
Modification of the oil usage counter value. Exchanging the gearbox ECU: - Note down the gearbox counter value. - Transfer the value read into the the new gearbox ECU. Exchanging the gearbox: - Initialise the oil usage counter to 0. Draining the gearbox: - Initialise the oil usage counter (follow the diagnostic tool procedure).
176
C3
An excessive oil level can result in the following consequences: - Excessive heating of the oil. - Oil leaks. An insufficent level causes the destruction of the gearbox. Top up the level of oil in the gearbox (if necessary). Check using a diagnostic tool. Read the fault codes (engine and gearbox). Absence of fault codes. Carry out parameter measures, actuator tests and a road test. Presence of fault codes. Carry out the necessary repairs. Delete the fault codes. Carry out a road test to check the repair and, if need be, modify the gearbox ECU parameters (this is essential after an initialisation of the ECU).
177
C3
Downloading. Updating the gearbox ECU by downloading: - Follow the procedure using the diagnostic tool. The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU. Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU. CLUTCH GEARBOX TRANSMISSION After the downloading operation, carry out the following: - A clearing of faults. - An initialisation of the auto-adaptives. - A writing of the value of the oil usage counter previously read. - A road test. ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
Using PROXIA. Access to reading and recording of the oil counter is via the menu: - Configuration (integrated circuit button)/Oil counter. Adjustment of the oil counter value is done in incremental steps of 2750 units.
Using LEXIA. Access to reading and recording of the oil counter is via the menu: - Oil counter. Adjustment of the oil counter value is done by entering directly the 5 figures of the oil counter.
178
C3
(1) Oil flow modulation electrovalve fixing (2) Heat exchanger fixing (3) Output speed sensor fixing
B2CP3EDD
: 1 0,2 :51 : 1 0,2 : 1 0,2 : 4 0,2 : 2,4 0,4 : 0,8 0,1 CLUTCH GEARBOX TRANSMISSION
(4) Output speed sensor fixing (5) Oil overflow and drain fixing (6) Oil level plug (7) Oil pressure sensor fixing
B2CP311D
179
C3
: 1 0,1 : 3 0,3
: 0,8 0,2
: 5,2 1
180
C3
B: DW10 engine Hydraulic block fixing. Centre the hydraulic block, using screws (11) and (12). Pre-tighten (no strict order) Slacken Tighten (respect the order indicated) NOTE: The screw (11) is shouldered. (13) Fixing of selector lever position switch (14) Oil filler plug
B2CP3EGC
181
C3
Position M: Manual (this position lets the driver select his own gears in sequential mode by pulling the gear selector to M- or pushing it to M+). NOTE: Only the positions P or N authorise the starting of the engine. In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status.
182
C3
NOTE: The vehicle is equipped with the shift loc: you have to switch on the ignition and press the brake pedal to unlock the selector lever from position P. Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal programme: Operates as the default programme (eco law, autoadaptive mode). - Sport programme (a): Permits a more dynamic, sporty performance. - Snow programme (b): Facilitates starting and adhesion on slippery surfaces. NOTE: To return to the normal programme, press a second time on the sport switch or snow switch. CLUTCH GEARBOX TRANSMISSION
B2CP3DKD
183
C3
Gearbox end. The automatic gearbox is controlled by a cable. c or d Push-button. (1) Control lever with ball-joint CLUTCH GEARBOX TRANSMISSION
B2CP3H8C
(2) Automatic adjustment (pull out the button to adjust the control, push it in to lock the adjustment of the control) (3) Sleeve stop (4) Selection control locking clip (5) on the sleeve stop (3)
184
C3
NOTE: The shift lock is a system that locks the gear selection lever in position P. Unlocking the SHIFT LOCK (normal operation). - Switch on the ignition. - Press the brake pedal and keep it pressed. - Move the gear selection lever out of position P. Unlocking the SHIFT LOCK (with an operating fault). NOTE: It is impossible to unlock the shift lock with the Normal operation method. The fault may originate from one of the following components: - Shift lock. - Gear lever position switch. - Automatic gearbox ECU. - Electrical harnesses. - Battery voltage. Remove: - The gear lever knob (1) (pull upwards). - The cover (2) (Unclip). - The top of the central console (3). - Unlock the shift lock (4) with the aid of a screwdriver. - Move the gear selection lever out of position P.
C5FP0ETC
B2CP3GZC
185
C3
B2CP3AYD
186
C3
Checking the oil level. Prior conditions: - Vehicle in horizontal position. - Check gearbox is not in back-up mode. - Remove the oil filler cap (2). - Add 0.5 litres extra oil into the gearbox. - Foot on the brake, change through all the gears. - Selection lever in position "P". - Engine running, at idle. - Oil temperature: 60C (+8C; -2C). - Remove the oil level plug (3). C3
B2CP3AZD
TU3 engines:
Dimension X = 81 mm.
187
C3
Refit the oil level plug (3) (equipped with a new seal), tighten to 2,4 0,2 m.daN. Checking the oil level (continued). Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4 0,2 m.daN. An excessive level of oil can lead to the following consequences: - Oil heating up abnormally, - Oil leaks. A level that is too low will result in the destruction of the gearbox.
188
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Vehicles Gearbox Engines TU1/3 - ET3 DV4 TU5 BE4/5 DV4 - DV6 Driveshaft bearing NO Driveshaft nut 24,5 0,5
C2 - C3 - C3 PLURIEL
Gearbox oil seal mandrels RH side LH side Tool kit
C2 C3 C3 Pluriel
MA/5
7114-T.X
7116-T
C3
AL4
TU3JP
1,8 0,1
32,5 2,5
(-) 0338
(-) 0338 J1 + (-) 0338 J3 Tightening torque (m.daN) for wheel bolts: C2 C3 C3 PLURIEL = 9 1.
189
C2 - C3
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. Link tools [1] and [2] in series between the fuel high pressure pump and the fuel filter. ESSENTIAL: Check that the tool [2] is clean. Check the negative pressure according to the table below: Vacuum 10 5 cmHg 20 5 cmHg 60 5 cmHg Observations Engine driven by the starter motor Engine running under full load Supply circuit obstructed (full tank strainer, piping, fuel filter)
B1BP2NWC
135
C3
INJECTION
B1BP2PHC
136
C3
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. Remove the air filter duct. Link tool [1] in series, downstream of the injectors, between the fuel high pressure pump and the fuel filter at a and b. WARNING: Any checking of pressure downstream of the fuel filter is prohibited. Switch on the ignition. Check the pressure: Vacuum measured by the pressure gauge [2] 10 0,5 cmHg 20 0,5 cmHg 60 0,5 cmHg : Checks. : Engine driven by the starter motor. : Engine running under full load : Supply circuit obstructed (full tank strainer, piping, fuel filter).
B1CP0GFD
137
INJECTION
C2 - C3
INJECTION
B1BP2NXD C5FP0F5C
C3
C5FP0EJC
B1BP2NBD
INJECTION
C3
IMPERATIVE: Respect the safety and cleanliness requirements. Preparation. INJECTION IMPERATIVE: Respect the following test conditions: - Engine at operating temperature. - Vehicle in running order. - Engine under full load. Connect the diagnostic tool to the vehicle's diagnostic socket, carry out parameter measures. Mode of operation. Start the engine. Engage first gear, start the vehicle. Engage the gears up to third gear. Decelerate to an engine speed of 1000 rpm. Check the pressure: 0,6 0,05 bar (1500 rpm). Accelerate freely (change from fourth gear to third gear). Check the pressure: 0,9 0,05 bar (between 2500 and 3500 rpm).
140
C2 - C3
: FACOM DA 16 INJECTION
B1HP1K8D
141
C3
INJECTION
B1HP1UGC B1HP22RC
Checks. Vacuum pump. Connect the tool [1] onto the vacuum pump (1). Start the engine. The vacuum value should be 0,9 0,1 bar at idling speed (after 30 seconds of running). NOTE: The EGR valve is not linked to the air supply circuit. The EGR valve is piloted by the engine ECU. Turbo pressure regulator valve. - Connect the tool [1] on the valve (2). - Apply a vacuum of 0.8 bar. - The rod "a" move 6 2 mm.
142
C2 - C3
B1HP15GD
Engine: DV4TED4
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection (HDi) engines. EGR valve. Connect tool [1] on the capsule take-off (2). Apply a vacuum of approx. 0,6 bar several times to activate the rod a. In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. Regulation electrovalve (EGR) (engine: 8HX - 8HW). Check to be performed between the electrovalve (1) and the EGR valve (2). Link the tool [1] in series between the electrovalve (1) and the capsule (2). Compare the values noted with those in the table below. Regulation electrovalve (EGR) (engine: 8HV - 8HY). Check to be performed between the electrovalve (2) and the EGR valve (1). Link the tool [1] in series, between the electrovalve (2) and the capsule (1). Compare the values noted with those in the table below.
143
INJECTION
SPARKING PLUGS
Vehicles Models 1.1i C2 IGNITION C3 C3 Pluriel 1.4i 1.6i 16V 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4i 1.6i 16V Engine type HFX KFV NFU HFX KFV KFU NFU KFV NFU FR 7 DE VR 8 SE FR 7 ME FR 7 DE FR 7 ME 0,9 0,1 0,9 0,05 RFN 58 HZ RFN 58 LZ RFN 58 HZ RC 8 YLC FR 7 ME 0,9 0,1 RFN 58 HZ RFN 58 LZ 0,9 0,05 RC 8 YLC 0,9 0,05 2.5 0,2 mda.N BOSCH FR 7 DE Electrode gap setting EYQUEM RFN 58 LZ Electrode gap setting CHAMPION RC 8 YLC Electrode gap setting Tightening torque
144
C2
Tyres inflated to correct pressures.
AXLE GEOMETRY
Conditions for checking and adjusting Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height
E1APOBZD
Front height L1 H1 = R1 L1 H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe. AXLES SUSPENSION STEERING
Rear height L2 H2 = R2 + L2 H2 = Measurement between the measuring zone underneath the rear sill and the ground. R2 = Rear wheel radius under load. L2 = Distance between the wheel axis and the measuring zone underneath the rear sill. 190
AXLE GEOMETRY
C2
B3CP07SD
[1] Gauge for measuring the wheel radius, 4 bolts, tool 8006-T Measure the radius of the front wheel R1 - Calculate dimension H1 = R1-L1 Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 Except CRD vehicles (*) Except CRD vehicles (*) TU1JP/3JP - DV4TD TU5/JP4/JP4S TU1JP/3JP - DV4TD TU5/JP4/JP4S Value at reference Value at reference height L1 = 142,5 mm L1 = 152,5 mm height L2 = 52 mm L2 = 42 mm (+ 6 - 8 mm) (+ 10 - 6 mm) CRD vehicles (*) CRD vehicles (*) TU1JP/3JP - DV4TD TU5/JP4/JP4S TU1JP/3JP - DV4TD TU5/JP4/JP4S L1 = 132,5 mm L1 = 152,5 mm L2 = 62 mm L2 = 42 mm Compress the suspension to obtain the calculated values.The height difference between the two axle wheel should be less than 10 mm. (*) = CRD: Difficult road conditions (for a type of vehicle with axles and suspensions adapted for driving on rough road surfaces). 191
C2
Front axle Dissymmetry of lower castor at 0 30'. Dissymmetry of lower camber at 0 18'. Distribute symmetrically, LH / RH wheel, the total tracking value. TU1JP/3JP - DV4TD Vehicle Tracking Adjustable All Types mm 0 21 018 009 Adjustable 21 018 009 Adjustable 21 018 009 358 Castor ( 018) Camber ( 030) Non adjustable - 031 TU5JP4 Non adjustable 4 - 032 TU5JP4S Non adjustable 4 - 027
AXLE GEOMETRY
Rear axle Dissymmetry of lower camber at 0 18.
All types (except CRD vehicles) TU1JP/3JP - DV4TD Pivot angle 030 Tracking Non adjustable 1126 5,5 1 053 009 TU5JP4/JP4S Non adjustable 1135 5,8 1 049 009 -131 - 130 Camber
All Types
mm 0
All Types
mm 0
AXLE GEOMETRY
Front axle Dissymmetry of lower castor at 0 30'. Dissymmetry of lower camber at 0 18'. Distribute symmetrically, LH / RH wheel, the total tracking value. TU1JP/3JP - DV4TD Vehicle Tracking Adjustable All Types mm 0 21 018 009 Adjustable 21 018 009 354 Castor ( 018) Camber ( 030) Non adjustable - 028 TU5JP4 Non adjustable 4 - 032 1135 5,8 1 049 009 Pivot angle 030 Tracking Non adjustable 1115 5,2 1 050 009 TU5JP4 Non adjustable -131 - 128 Rear axle Dissymmetry of lower camber at 0 18.
C2
All Types
mm 0
+= -=
TOE-IN TOE-OUT
C2
FRONT AXLE
Tightening torques (m.daN). (1) Nut fixing suspension leg on body : 6,5 0,6 (2) Damper : (3) Anti-roll bar link rod upper ball-joint : 3,2 0,3 (4) Suspension leg pivot : 5,4 0,5 (5) Anti-roll bar link rod lower ball-joint : 3,2 0,3 (6) Anti-roll bar bearing fixing on subframe : 8 0,8 (7) Hub nut : 24,5 0,5 (8) Wheel bolt :91 (9) Subframe to bodyshell fixing screw : 10 1 (10) Anti-roll bar : (11) Pivot lower ball-joint fixing on lower arm : 5,5 0,5 (12) Pivot lower ball-joint fixing : 4 0,4 (13) Lower arm front and rear mounting fixing : 14 0,4 (14) Stabiliser bar screw : 6,6 0,7 (15) Steering ball-joint fixing : 3,5 0,3 Anti-roll bar Private vehicles Europe Diameter (mm) Colour TU1JP - TU3JP 18 Violet TU5JP4 20 Green TU5JP4S 21 Orange TU1JP - DV4TD 19 Blue Entreprise vehicles Diameter (mm) Colour TU1JP - DV4TD 18 Violet CRD vehicles Diameter (mm) Colour TU1JP - DV4TD 18 Violet TU4JP4 20 Green 194
B3CP07RP
REAR AXLE
Tightening torques (m.daN) (25) Rear axle fixing screw (26) Anti-roll bar (27) Rear axle crossmember (28) Rear suspension arm silentblock yoke (29) Rear suspension arm silentblock (30) Yoke / suspension arm fixing screw (31) Rear suspension arm (32) Stub axle bearing nut (33) Damper (34) Damper upper fixing (35) Damper lower fixing (36) Suspension springs (37) Travel stop (38) Secondary brake cable guide support Private vehicles Europe TU1JP - TU3JP DV4TD TU5JP4 TU5JP4S Entreprise vehicle TU1JP - DV4TD CRD vehicles TU1JP - DV4TD TU5JP4 195 : : : : : : : : : : : : : : 10 1
C2
B3DP09UP
Anti-roll bar Diameter (mm) 20,5 (tubular) 23,5 (tubular) 25 (solid) 26 (tubular) Diameter (mm) 20,5 (tubular) Diameter (mm) 20,5 (tubular) 25,5 (solid)
C2
SUSPENSION
Front axle (1) Nut fixing suspension leg on body (2) Damper (16) Cup (17) Damper nut (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod protector (24) Travel stop : 6,5 0,6 : 6,5 0,6
B3BP180D
196
C2
B3EP13GD
B3EP13HC
Tightening torques (m.daN). (1) Steering wheel fixing (2) Steering column fixing on support (3) Steering cardan fixing : 2 0,3 : 2,2 0,5 : 2,2 0,2 197
Identification AXLES SUSPENSION STEERING Identified by the colour of the ring at a. Left hand drive Right hand drive : BLUE ring. : WHITE ring
C2
B3EP13JD
TU1JP - TU3JP - DV4TD Electric motor Steering rack travel Steering ratio AXLES SUSPENSION STEERING Number of rotations of steering wheel Inner angle of lock Outer angle of lock 60 A 2x72 1/45,6 3,2 38 3224
TU5JP4 65 A 2x64
TU5JP4S Connectors. (6) Supply of electric assistance motor 1/49,38 2,6 3230 2842 (7) Torque sensor signals
2,8
198
C2
B3EP13KC
B3EP13LC
Supplier: KOYO. The steering assistance is provided by the assistance motor (12), controlled by the ECU. Power delivered to the assistance motor (12) depends on: - Speed of the vehicle. - Torque applied on the steering wheel. 199
Only one ECU version, whatever the engine-type. The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply. AXLES SUSPENSION STEERING - (13) Electric power steering ECU supply. - (14) Control signals. After changing the electric power steering ECU, it is necessary to perform a configuration.
C2
B3EP13UC
B3EP13VD
200
AXLE GEOMETRY
Conditions for checking and adjusting Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height
C3
E1AP09MD
201
Front height L1 H1 = R1 - L1 H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe.
Rear height L2 H1 = R1 - L1 H2 = Measurement between the measuring zone underneath the rear sill and the ground. R2 = Rear wheel radius under load. L2 = Distance between the wheel axis and the measuring zone underneath the rear sill.
C3
AXLE GEOMETRY
Checks at reference height
B3CP07SD
Measuring front height Z1 = Measuring zone underneath the front subframe. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1L1 Value at reference height (+ 6 - 8 mm) AXLES SUSPENSION STEERING All types except CRD (*) Raised suspension Administration vehicle C3 version XTR L1 = 142,5 mm CRD (*) Raised suspension Administration vehicle C3 version XTR L1 = 132,5 mm
Measuring rear height Z2 = Measuring zone underneath the rear sill.. Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 Value at reference height (+ 10 - 6 mm) All types except CRD (*) Raised suspension Administration vehicle C3 version XTR L2 = 52 mm CRD (*) Raised suspension Administration vehicle C3 version XTR L2 = 62 mm
[1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T or 8006-T (according to version).
(*) = CRD: Difficult road conditions. Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads. Compress the suspension to obtain the calculated values. The height difference between the two axle wheel should be less than 10 mm. 202
AXLE GEOMETRY
C3
Dissymmetry of lower castor at 0 30'. Dissymmetry of lower camber at 0 18'. (*) CRD = Difficult road conditions. ESSENTIAL: Distribute symmetrically, LH / RH wheel, the total tracking value.
+= -=
TOE-IN TOE-OUT
C3
AXLE GEOMETRY
All types except: CRD (*), Raised suspension, Administration vehicle, C3 version XTR Front axle Wheel Castor Camber Pivot angle Engines Tracking dimensions ( 018') ( 030') ( 030') (in inches) Adjustable Non adjustable mm -21 TU1JP 14 TU3JP BV MA (except Exclusive) 0 - 019' 010' 3 57' mm -21 TU3JP BV AL4 0 - 018' 009' 15 - 028' 1124' TU3JP BV MA (except Exclusive) mm -21 ET3J4 - TU5JP4 0 - 018' 009' 3 54' DV4TD - DV4TED4 mm -21 16 DV6ATED4 0 - 017' 009' Rear axle Non adjustable Tracking Camber ( 018') TU1JP mm 5,5 1 14 TU3JP BV MA (except Exclusive) 0 053' 010' mm 5,5 1 TU3JP BV AL4 0 050' 009' 15 - 130' TU3JP BV MA (except Exclusive) mm 5,5 1 ET3J4 - TU5JP4 0 050' 009' DV4TD - DV4TED4 mm 5,5 1 16 DV6ATED4 0 047' 009' 204
AXLE GEOMETRY
C3
14 15
mm 0 mm 0
All types except: CRD (*), Raised suspension, Administration vehicle, C3 version XTR Front axle Castor Camber Pivot angle Tracking ( 018') ( 030') ( 030') Adjustable Non adjustable -21 - 019' 010' 3 53' - 026 1114' -21 - 018' 009' Rear axle Non adjustable Tracking Camber ( 018') 5,2 1 050' 010' - 128' 5,2 1 047' 009' AXLES SUSPENSION STEERING
205
C3 PLURIEL
AXLE GEOMETRY
Conditions for checking and adjusting
Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point (see corresponding operation). Vehicle heights at reference height
E1AP0AUD
Front height L1 H1 = R1 - L1 H1 = Measurement between the measuring zone underneath the front subframe and the ground. R1 = Front wheel radius under load. L1 = Distance between the wheel axis and the measuring zone underneath the front subframe.
Rear height L2 H2 = R2 + L2 H2 = Measurement between the measuring zone underneath the rear sill and the ground. R2 = Rear wheel radius under load. L2 = Distance between the wheel axis and the measuring zone underneath the rear sill.
206
AXLE GEOMETRY
Checks at reference height
C3 PLURIEL
B3CP07SD
Measuring front height Z1 = Measuring zone underneath the front subframe. Measure the radius of the front wheel R1 - Calculate dimension H1 = R1-L1 Value at reference height (+ 6 - 8 mm) All Types L1 = 132,5 mm
Measuring rear height Z2 = Measuring zone underneath the rear sill. Measure the radius of the rear wheel R2 - Calculate dimension H2 = R2+L2 Value at reference height (+ 10 - 6 mm) All Types AXLES SUSPENSION STEERING L2 = 47 mm
[1] Gauge for measuring the wheel radius, 4 bolts, tool 4003-T
(*) = CRD : Difficult road conditions. Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads. Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than 10 mm. 207
C3 PLURIEL
Front axle Dissymmetry of lower castor at 0 30'. Dissymmetry of lower camber at 0 18' Distribute symmetrically, LH / RH wheel, the total tracking value.
AXLE GEOMETRY
Rear axle
All types Vehicle Tracking Adjustable All Types mm 0 -21 - 018 009 353 Castor ( 018) Camber ( 030) Non adjustable - 026 Pivot angle ( 030) Tracking Non adjustable 1114 5,7 1 051 009 - 130 Camber ( 018)
+= -=
TOE-IN TOE-OUT
FRONT AXLE
C3 - C3 PLURIEL
Tightening torques (m.daN). (1) Nut fixing suspension leg on body (2) Suspension leg (3) Anti-roll bar link rod upper ball-joint (4) Suspension leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing Diameter (mm) C3 All types C3 Pluriel 20 Green 19 : : : : : : : : : : : : : : : 6,5 0,6 3,2 0,3 5,4 0,5 3,2 0,3 8 0,8 24,5 0,5 91 10 1 5,5 0,5 4 0,4 14 0,4 6,6 0,7 3,5 0,3 Colour Blue AXLES SUSPENSION STEERING
Anti-roll bar
B3CP07RP
209
C3 - C3 PLURIEL
REAR AXLE
Tightening torques (m.daN). (1) Rear axle fixing screw (2) Anti-roll bar (3) Rear axle crossmember (4) Rear suspension arm rubber mounting yoke (5) Rear suspension arm rubber mounting (6) Yoke / suspension arm fixing screw (7) Rear suspension arm (8) Stub axle bearing nut (9) Damper (10) Damper upper fixing (11) Damper lower fixing (12) Suspension spring (13) Travel stop (14) Secondary brake cable guide and its support : : : : : : : : : : : : : : 10 1
All types
26 (tubular)
210
SUSPENSION
Front axle (1) Nut fixing suspension leg on body (2) Damper (3) Anti-roll bar link rod upper ball-joint (4) Suspension leg pivot (5) Anti-roll bar link rod lower ball-joint (6) Anti-roll bar bearing fixing on subframe (7) Hub nut (8) Wheel bolt (9) Subframe to bodyshell fixing screw (10) Anti-roll bar (11) Pivot lower ball-joint fixing on lower arm (12) Pivot lower ball-joint fixing (13) Lower arm front and rear mounting fixing (14) Stabiliser bar screw (15) Steering ball-joint fixing Pivot Engines C3 C3 Pluriel
B3CP07RP
C3 - C3 PLURIEL
: : : : : : : : : : : : : : : 6,5 0,6 3,2 0,3 5,4 0,5 3,2 0,3 8 0,8 24,5 0,5 91 10 1 5,5 0,5 4 0,4 14 0,4 6,6 0,7 3,5 0,3
Bearing diameter 72
All types
211
C3 - C3 PLURIEL
SUSPENSION
Front axle (1) Nut fixing suspension leg on body (2) Damper (16) Cup (17) Damper nut (18) Damper cup (19) Ball bearing (20) Spring thrust cup (21) Travel stop cup (22) Suspension spring (23) Damper rod protector (24) Travel stop : 6,5 0,6 : 6,5 0,6
B3BP180D
212
SUSPENSION
Rear axle
C3 - C3 PLURIEL
B3CP09UP
213
(25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38)
Rear axle fixing screw Anti-roll bar Rear axle crossmember Rear suspension arm silentblock mounting yoke Rear suspension arm silentblock Suspension arm fixing screw on yoke Rear suspension arm Stub axle bearing nut Damper Damper upper fixing screw Damper lower fixing screw Suspension spring Travel stop Secondary brake cable guide support
: : : : : : : : : : : : : :
10 1
C3 - C3 PLURIEL
B3EP13GD
B3EP13HC
Tightening torques (m.daN). (1) Steering wheel fixing (2) Steering column fixing on support (3) Steering cardan fixing 214 : 2 0,3 : 2,2 0,5 : 2,2 0,2 AXLES SUSPENSION STEERING
Identification. Identified by the colour of the ring at a. Left hand drive Right hand drive : BLUE ring. : WHITE ring.
C3 - C3 PLURIEL
Tightening torques (m.daN). (4) Ball-joint fixing on pivot (5) Steering rod lock-nut (8) Threaded washer (9) Stud (10) Flat washers (11) Fixing of mechanism on subframe
B3EP13JD
C3 Pluriel C3 TU3JP - TU5JP4 - DV4TD Electric motor Steering rack travel Steering ratio Number of rotations of steering wheel Inner angle of lock Outer angle of lock 60 A 2x72 45,6/1 3,2 38 3224 215 2,8 3230 2842 TU3JP (BVA) - ET3J4 DV4TD 65 A 2x64 Connectors. (6) Supply of electric assistance motor AXLES SUSPENSION STEERING (7) Torque sensor signals
C3 - C3 PLURIEL
B3EP13KC
B3EP13LC
Supplier: KOYO. The steering assistance is provided by the assistance motor (12), controlled by the ECU. Power delivered to the assistance motor (12) depends on: - Speed of the vehicle. - Torque applied on the steering wheel. 216 AXLES SUSPENSION STEERING
Electric power-assisted steering ECU. Only one ECU version, whatever the engine-type. The electric power steering ECU is linked to the following connectors: - (6) Assistance motor supply. - (13) Electric power steering ECU supply. - (14) Control signals. After changing the electric power steering ECU, it is necessary to perform a configuration (see corresponding operation).
C3 - C3 PLURIEL
Preliminary operation. Raise and support the vehicle on a two-column lift. Remove, on the RH side of the steering rack: - Clip (1). - Clip (2). Release the steering rack protection gaiter.
B3EP13UC
Setting. Move the steering to full left hand lock. Measure the dimension X. Move the steering to full right hand lock. Measure the dimension Y. Calculate the dimension: L = (Y - X): 2. Refit: - The steering rack protection gaiter. - New clips (1) and (2). AXLES SUSPENSION STEERING
B3EP13VD
217
BRAKES FT
C2
TU1JP
TU3JP
DV4TD
Master cylinder mm Caliper makes/pistons Disc Plain Disc thickness/minimum thickness Maximum run-out (mm) Difference in max. thickness on same circumference (mm) Brake pad supplier/grade Original thickness/minimum thickness Original drum/maximum RR mm Width Supplier/grade Master vac
20,6 203,2 LUCAS.TRW-/-C 48/13-/-48 266 13/11 0,05 0,01 TEXTAR-/-T 4144 13/3 203/205 38 DON-8259/1
218
C2
DV4TD
219
BRAKES
BRAKES
C2
BRAKE SPECIFICATIONS
Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at X. - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels. The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE: REF = Electronic Brakeforce Distribution.
B3FP7C7D
220
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (drum brakes at the rear)
C2
B3FP7C8D
221
BRAKES
BRAKES
C2
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (disc brakes at the rear)
B3FP7C9D
222
BRAKE SPECIFICATIONS
Brake pedal gear Front brakes Rear brakes
C2
B3FP166D
B3FP164C
B3FP165C
Tightening torques (m.daN). (16) Servo fixing (17) Fixing on master cylinder : 2,2 0,3 : 2 0,5 (12) Yoke fixing on caliper (13) Yoke fixing on caliper 223 : 10,5 1 : 3 0,3 (14) Rear caliper fixing on arm (15) Yoke fixing on caliper : 5,3 0,5 : 3,8 0,3
BRAKES
BRAKES
C2
HANDBRAKE (adjustment)
Adjustment. Lift and chock the vehicle. Remove: - The rear cover (8). - The nut (9). - The handbrake trim (6). - The gear lever gaiter (5). - The front cover (3). - The screws (1). Disconnect the connectors of the following components: - The cigar lighter (2). - The electric window buttons (4). Remove the central console (7). WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever. Press gently on the brake pedal (then repeat the operation 3 times). Pull vigorously on the handbrake lever 4 or 5 times.
C5FP0ELD
224
HANDBRAKE (adjustment)
C2
Adjustment (continued). A: Drum brakes B: Disc brakes (10) Nut for adjusting cable tensions Remove: - The rear wheels. - The drums (according to version). Release the handbrake. Use a gauge set to measure at a the travel of the lever from its stop. Adjust the nut (10) to obtain a travel of less than or equal to 1 mm at a. Refit the brake drums without tightening them (according to version). Action the handbrake lever 8 times with an effort of 40 m.daN. With the handbrake released, check the travel of the lever at a, using a gauge set. NOTE: The travel should be less than 1 mm and more than 0,05 mm. Refit: - The brake drums. - The wheels. - The central console. Check the operation of the handbrake.
B3FP16ED
225
BRAKES
BRAKES
C2
B3FP15XC
226
C2
Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order: B3FP15YC
227
BRAKES
BRAKES
C2
B3FP160C
228
C3
DV6ATED4 9HX
LUCAS/TRW C 54/22/54
266 22/20
Disc thickness/minimum thickness Brake pad supplier/grade mm RR Make Brake lining grade Drum/max. thickness Width
Without ABS REF: Braking compensators on vehicles without ABS REF (**) engines TU1JP TU3JP DV4TD 9666 LUCAS Type CICR (***) Cut-off pressure (bar) 35 Braking compensators on vehicles without ABS REF (**) engines TU1JP TU3JP DV4TD 9666 LUCAS Type CICR (***) Cut-off pressure (bar) 27. (*) = STT = Stop and start. (**) REF = Electronic brakeforce distribution. (***) CICR = Compensator integral to the wheel cylinder.
229
BRAKES
BRAKES
C3
TU1JP Engines Master cylinder Master vac Caliper makes/ pistons Disc Plain FT Disc thickness/min. thickness Disc Ventilated mm Disc thickness/min. thickness Brake pad supplier/grade Cylinder or caliper mm Disc Plain RR Disc thickness/min. thickness Drum/max. thickness mm Width Make Brake lining grade mm HFX
266 22/20 TEXTAR T 4144 LUCAS C38 HR 9/13/38 247 9/7 203/205/38 DON 8259 GALFER G 4554 203/205/38 DON 8259
266 22/20
With ABS REF: Braking compensator integral to the wheel cylinder on vehicles with ABS REF all engine-types. The main brake compensator and limiter functions are assured by the ABS REF system. (***) = RPO 9898. 9898 = GALFER/ G 4554. (*) = STT = Stop and start. (**) = With emergency braking system (AFU).
230
BRAKE SPECIFICATIONS
Braking circuit without ABS - REF (drum brakes at the rear) Braking system specifications - Braking circuit at X. - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*).
C3
- Handbrake lever controlling cables acting on the rear wheels. The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE: REF = Electronic Brakeforce Distribution.
B3FP161D
231
BRAKES
BRAKES
C3
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (drum brakes at the rear)
B3FP162D
232
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (disc brakes at the rear)
C3
B3FP163D
233
BRAKES
BRAKES FT
C3 PLURIEL
Disc thickness/minimum thickness Brake pad supplier/grade mm Cylinder or caliper Disc Plain
RR Disc thickness/minimum thickness mm Make Brake lining grade Drum/max. thickness Width
Without ABS REF: Braking compensators on vehicles without ABS REF. (*) engines TU3JP DV4TD CICR. (**) Cut-off pressure (bar) 27. (*) REF = Electronic brakeforce distribution (**) CICR = Compensator integral to the wheel cylinder. With ABS REF: Vehicles with ABS REF all engine-types. The main brake compensator and limiter functions are assured by the ABS REF system.. (***) = With emergency braking system (AFU).
234
BRAKE SPECIFICATIONS
Braking circuit without ABS - REF (drum brakes at the rear)
C3 PLURIEL
Braking system specifications - Braking circuit at X. - Front brakes with ventilated discs (*). - Rear brakes with eitther drums or discs (*). - Handbrake lever controlling cables acting on the rear wheels. The compensator and main brake limiter functions are assured by the ABS EBD system. NOTE: REF = Electronic Brakeforce Distribution.
B3FP7BSD
235
BRAKES
BRAKES
C3 PLURIEL
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (drum brakes at the rear)
B3FP7BTD
236
BRAKE SPECIFICATIONS
Braking circuit with ABS - REF (disc brakes at the rear)
C3 PLURIEL
B3FPBUD
237
BRAKES
BRAKES
C3 - C3 PLURIEL
Brake pedal gear
BRAKE SPECIFICATIONS
Front brakes Rear brakes
B3FP166D
B3FP164C
B3FP165C
Tightening torques (m.daN). (16) Servo fixing (17) Fixing on master cylinder : 2,2 0,3 : 2 0,5 (12) Yoke fixing on caliper (13) Yoke fixing on caliper 238 : 10,5 1 : 3 0,3 (14) Rear caliper fixing on arm (15) Yoke fixing on caliper : 5,3 0,5 : 3,8 0,3
HANDBRAKE (adjustment)
Adjustment. Lift and chock the vehicle. Remove the access cover (1).
C3 - C3 PLURIEL
(2) Nut for adjusting the tension of the handbrake cables WARNING: Check that the brake cables are correctly routed under the vehicle. Slacken the handbrake lever. Press gently on the brake pedal (then repeat the operation 3 times). Pull vigorously on the handbrake lever 4 or 5 times.
B3FP79XC
239
BRAKES
BRAKES
C3 - C3 PLURIEL
HANDBRAKE (adjustment)
Adjustment (continued). A: Drum brakes B: Disc brakes (2) Nut for adjusting cable tensions. Remove: - The rear wheels. - The drums (according to version). Release the handbrake lever. Use a gauge set to measure at a the travel of the lever from its stop. Adjust the nut (2) to obtain a travel of less than or equal to 1 mm at a. Refit the brake drums without tightening them (according to version). Action the handbrake lever 8 times with an effort of 40 m.daN. With the handbrake released, check the travel of the lever at a, using a gauge set. NOTE: The travel should be less than 1 mm and more than 0,05 mm. Refit: - The brake drums. - The wheels. - The access cover (1). Check the operation of the handbrake. 240
B3FP79YD
C3 - C3 PLURIEL
: LURO or similar
Draining. Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). Disconnect the connector (4). Uncouple the pipe (2). Unscrew the shaft (3). Remove the reservoir (1). - Empty the brake fluid reservoir (1). - Clean the brake fluid reservoir (1). Refit: - The brake fluid reservoir (1). - The shaft (3). - Couple the pipe (2). - Reconnect the connector (4). Filling the braking system. WARNING: Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear. 241
B3FP15XC
BRAKES
BRAKES
C3 - C3 PLURIEL
Bleeding the primary braking circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). A: Rear brake caliper B: Rear brake drum Bleed screw (6). Bleed each wheel cylinder, proceeding in the following order: B3FP15YC
242
C3 - C3 PLURIEL
With the bleeding apparatus. Connect the bleeding apparatus [1] on the brake fluid reservoir (1). Adjust the apparatus pressure to 2 bars. For each circuit: - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus [1]. - Check the brake fluid level (should be between MINI level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE: Two operators are necessary. For each circuit: - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE: Recommence the process a second time if that is necessary. - Check the brake fluid level (should be between MINI level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid.
B3FP160C
243
BRAKES
AIR CONDITIONING
All types EUROPE C2 All types MERCOSUR 07/04 # All types EUROPE C3 C3 Pluriel All types MERCOSUR
500 25 gr
600 25 gr
244
C2 - C3 - C3 PLURIEL
Compressor (MANULLI seal)
IMPERATIVE: Removing-refitting the MANULLI seal: see corresponding operation. AIR CONDITIONING
The drive plate (1) is held on the aircon compressor shaft by ribs. New wiring (2). New seals (3) (MANULLI). Identification label (4) for aircon compressor. 245
C2
Note: The pollen filter is located in the engine compartment on the RH side.
Removing. To remove: - Pull on the tab of the plastic cover (1) at a. - Tilt the flap (2). Remove the pollen filter (3). AIR CONDITIONING
C4AP1BRC
C4AP1BSC
C4AP1BTC
246
C3 - C3 PLURIEL
Note: The pollen filter is located in the engine compartment on the RH side.
Removing. Remove: - The three screws (1). - The plastic cover (2). Tilt the flap (3). Remove the pollen filter (4). AIR CONDITIONING
C4AP16BC
C4AP169C
C4AP16AC
247
C2 - C3 - C3 PLURIEL
[1] Charge station [2] TORX adaptor [3] Inertia extractor [4] Endpiece 20 [5] Set of plugs [6] Circlip pliers
Removing. Depressurise the aircon circuit, using tool [1]. Remove the grille. At a, remove the pin and the plastic cover. Unclip the condenser at b and c, using a screwdriver. Tilt the condenser towards the front. Lift and release the condenser. Clean the area around the cap (3). Remove the plastic cap (3), using tool [2]. Remove the safety circlip (4), using tool [6]. Position the tool [3] and [4] in the aperture of the cartridge (5). Extract the cartridge from the reservoir (6), using tool [3] and [4]. Block the reservoir (6), using tool [5].
C4AP163C C4AP164C C4AP165C C4AP166C
AIR CONDITIONING
248
C2 - C3 - C3 PLURIEL
plastic cap (3), using tool [5] - Tighten to 1,2 0,1 m.daN. condenser (reclip, pushing at b and c). plastic cover and the pins at a. grille (2). screws (1).
Proceed to: - Recharge the circuit (see corresponding operation). - Check the operation of the air conditioning (see corresponding operation).
C4AP167C C4AP165C C4AP163C C4AP164C
249
AIR CONDITIONING
WARNING: Not more than 5 minutes should elapse between the removal of the cartridge (6) from its packaging and its being fitted.
250
251
AIR CONDITIONING
E5AP2N5D
E5AP2N4D
252
E5AP2FAC
253
Origins Lack of aircon fluid in the aircon condenser (should be more than 150 grammes) Lack of aircon fluid in the aircon condenser (should be around 100 to 150 grammes) Correct quantity Excess aircon fluid in the aircon condenser
Blown air temperature u. The blown air temperature should be between 2C and 10C. 254
Over-heating (SC). The over-heating represents the difference between the aircon fluid temperature at the evaporator outlet and the evaporation temperature. The over-heating gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit. AIR CONDITIONING Values for over-heating (SC). Values s 2 < SC < 15C SC > 15C SC < 2C Correct quantity Lack of aircon fluid in the cooling circuit Excess aircon fluid in the cooling circuit Add aircon fluid Remove aircon fluid Origins Solutions
Blown air temperature u. The blown air temperature should be between 2C and 10C.
E5AP2FBC
255
E5AP2FCD
x Check satisfactory y Lack of aircon fluid in the aircon circuit z Excess aircon fluid in the aircon circuit aa Filtering and drying cartridge clogged ab Other problems (see table above) 256
257
258
259
NOTE: In all cases, measure the excessive heating (SC) and the blown air temperature. 260
C2
(1) High pressure valve (2) Low pressure valve (3) Pressostat (4) Filter Tightening torques (m.daN). (a) (b) (c) (d) (e) (f) : : : : : : 0,6 0,6 0,6 0,6 0,6 0,7 AIR CONDITIONING
C5HP19UP
261
C3 - C3 PLURIEL
(1) Low pressure valve (2) High pressure valve (3) Filter (4) Pressostat AIR CONDITIONING
C5HP17SP
Tightening torques (m.daN). (a) (b) (c) (d) (e) (f) : : : : : : 0,6 0,6 0,6 0,6 0,6 0,6
262